Absorbent article with a waistband and leg cuff having gathers

ABSTRACT

A disposable absorbent article comprising a first waist region, a second waist region, a crotch region disposed between the first waist region and second waist region; a first waist edge and a second waist edge; and a first longitudinal edge and a second longitudinal edge; the disposable absorbent article comprising a waistband and a leg gasketing system, wherein the waistband has a first gather count and the leg gasketing system has a second gather count such that the ratio of the first gather count to the second gather count is from about 0.75 to about 1.25.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. Nonprovisional applicationSer. No. 15/044,590, filed Feb. 16, 2016, which is a continuation ofU.S. Nonprovisional application Ser. No. 13/490,554, filed Jun. 7, 2012,which claims the benefit of U.S. Provisional Application No. 61/499,298,filed Jun. 21, 2011, which is herein incorporated by reference in itsentirety.

FIELD OF INVENTION

This invention relates to absorbent articles such as diapers havingimproved waistband properties that yield a more garment-like article.The absorbent article may have improved functional characteristics andcommunicative properties.

BACKGROUND OF THE INVENTION

Many diapers on the market today have waistbands or waist stretchelements in which a laminate of nonwovens and elastics strands arecombined with the chassis under some tension. Elastic strands are themost cost effective way to get stretch that exhibits little relax or setover time. Nonwovens are preferred for the exterior of the waistmaterial because it is breathable and softer than film alternatives.Some executions of applied waistband consist of elastics stretched inthe process and applied transversely to the length of the productsandwiched in between some body-facing and some garment-facing material.

Other executions create a laminate of elastic strands and nonwoven andapply the laminate to the chassis under contraction transversely to thelength of the product on the body-facing side such that the onlymaterial between the elastics and the body surface is a nonwoven in thewaistband region. It is known that contraction around the waist willimprove the perceived fit of the product by closing gaps at the back ofthe diaper, therefore, closing of these gaps could positively impactreal or perceived leakage/containment. It is also known that whenstrands of elastic are combined under strain with other oftennon-extensible materials and then allowed to relax, they will create alaminate that has gathers of a certain frequency and a resulting basisweight that is higher than the starting materials laid flat. Sincewaistbands or stretch elements around the waist are added at fullstrain, when pulled tight during application, the waistbands fullyextend or flatten around the waist area resulting in a basis weightaround the waist similar to the starting materials. Therefore, a needexists to improve waist and leg band construction and application to thechassis to improve fit and leakage containment.

SUMMARY OF THE INVENTION

The present invention relates to a disposable absorbent articlecomprising: a first waist region, a second waist region, a crotch regiondisposed between the first waist region and second waist region; a firstwaist edge and a second waist edge; a first longitudinal edge and asecond longitudinal edge, the disposable absorbent article comprising atleast one waistband.

In one embodiment, the waistband is comprised of a laminate comprising anonwoven material and at least one elastic strand, wherein the nonwovenmaterial and the elastic strand are combined under a first strain andthe waistband is attached to the disposable absorbent article under anapplied waistband strain, such that the waistband has a Full WaistbandConsolidation of greater than about 95% and/or an Extended WaistbandConsolidation of greater than about 35%.

In one embodiment, the disposable absorbent article comprises a firstwaistband near the first waist edge and a second waistband near thesecond waist edge, wherein the Front-to-Back Delta Chassis Contractionis greater than about 9.0%.

In one embodiment, the disposable absorbent article comprises a leggasketing system, wherein the waistband has a first gather count and theleg gasketing system has a second gather count such that the ratio ofthe first gather count to the second gather count is from about 0.75 toabout 1.25.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of an exemplary absorbent article.

FIG. 2 is a plan view of a waistband laminate suitable in one embodimentof the invention.

FIG. 3 is a plan view of an absorbent article suitable in one embodimentof the invention.

FIG. 4 is a schematic cross section view of an example of a folded outerleg cuff suitable in one embodiment of the invention.

FIG. 5 is a schematic cross section view of an example of a folded outerleg cuff suitable in one embodiment of the invention.

FIG. 6 is a schematic cross section view of an example of an absorbentcore suitable in one embodiment of the invention.

FIG. 7 is a schematic cross section view of another example of anabsorbent core suitable in one embodiment of the invention.

FIG. 8 is a schematic cross section view of another example of anabsorbent core suitable in one embodiment of the invention.

FIGS. 9a-d are schematic cross section views of waistband laminatessuitable in embodiments of the invention.

FIG. 10 is a schematic representation of a template.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the following terms shall have the meaning specifiedthereafter:

“Disposable,” in reference to absorbent articles, means that theabsorbent articles are generally not intended to be laundered orotherwise restored or reused as absorbent articles (i.e., they areintended to be discarded after a single use and, preferably, to berecycled, composted or otherwise discarded in an environmentallycompatible manner).

“Absorbent article” refers to devices which absorb and contain bodyexudates and, more specifically, refers to devices which are placedagainst or in proximity to the body of the wearer to absorb and containthe various exudates discharged from the body. Exemplary absorbentarticles include diapers, training pants, pull-on pant-type diapers(i.e., a diaper having a pre-formed waist opening and leg openings suchas illustrated in U.S. Pat. No. 6,120,487), refastenable diapers orpant-type diapers, incontinence briefs and undergarments, diaper holdersand liners, feminine hygiene garments such as panty liners, absorbentinserts, and the like.

“Proximal” and “Distal” refer respectively to the location of an elementrelatively near to or far from the longitudinal or lateral centerline ofa structure (e.g., the proximal edge of a longitudinally extendingelement is located nearer to the longitudinal centerline than the distaledge of the same element is located relative to the same longitudinalcenterline).

“Body-facing” and “garment-facing” refer respectively to the relativelocation of an element or a surface of an element or group of elements.“Body-facing” implies the element or surface is nearer to the wearerduring wear than some other element or surface. “Garment-facing” impliesthe element or surface is more remote from the wearer during wear thansome other element or surface (i.e., element or surface is proximate tothe wearer's garments that may be worn over the disposable absorbentarticle).

“Longitudinal” refers to a direction running substantially perpendicularfrom a waist edge to an opposing waist edge of the article and generallyparallel to the maximum linear dimension of the article. Directionswithin 45 degrees of the longitudinal direction are considered to be“longitudinal”

“Lateral” refers to a direction running from a longitudinal edge to anopposing longitudinal edge of the article and generally at a right angleto the longitudinal direction. Directions within 45 degrees of thelateral direction are considered to be “lateral.”

“Disposed” refers to an element being located in a particular place orposition.

“Joined” refers to configurations whereby an element is directly securedto another element by affixing the element directly to the other elementand to configurations whereby an element is indirectly secured toanother element by affixing the element to intermediate member(s) whichin turn are affixed to the other element.

“Film” refers to a sheet-like material wherein the length and width ofthe material far exceed the thickness of the material. Typically, filmshave a thickness of about 0.5 mm or less.

“Water-permeable” and “water-impermeable” refer to the penetrability ofmaterials in the context of the intended usage of disposable absorbentarticles. Specifically, the term “water-permeable” refers to a layer ora layered structure having pores, openings, and/or interconnected voidspaces that permit liquid water, urine, or synthetic urine to passthrough its thickness in the absence of a forcing pressure. Conversely,the term “water-impermeable” refers to a layer or a layered structurethrough the thickness of which liquid water, urine, or synthetic urinecannot pass in the absence of a forcing pressure (aside from naturalforces such as gravity). A layer or a layered structure that iswater-impermeable according to this definition may be permeable to watervapor, i.e., may be “vapor-permeable.”

“Extendibility” and “extensible” mean that the width or length of thecomponent in a relaxed state can be extended or increased.

“Elasticated” and “elasticized” mean that a component comprises at leasta portion made of elastic material.

“Elongatable material,” “extensible material,” or “stretchable material”are used interchangeably and refer to a material that, upon applicationof a biasing force, can stretch to an elongated length of at least about110% of its relaxed, original length (i.e. can stretch to 10 percentmore than its original length), without rupture or breakage, and uponrelease of the applied force, shows little recovery, less than about 20%of its elongation without complete rupture or breakage as measured byEDANA method 20.2-89. In the event such an elongatable material recoversat least 40% of its elongation upon release of the applied force, theelongatable material will be considered to be “elastic” or“elastomeric.” For example, an elastic material that has an initiallength of 100 mm can extend at least to 150 mm, and upon removal of theforce retracts to a length of at least 130 mm (i.e., exhibiting a 40%recovery). In the event the material recovers less than 40% of itselongation upon release of the applied force, the elongatable materialwill be considered to be “substantially non-elastic” or “substantiallynon-elastomeric”. For example, an elongatable material that has aninitial length of 100 mm can extend at least to 150 mm, and upon removalof the force retracts to a length of at least 145 mm (i.e., exhibiting a10% recovery).

“Elastomeric material” is a material exhibiting elastic properties.Elastomeric materials may include elastomeric films, scrims, nonwovens,and other sheet-like structures.

“Pant” refers to disposable absorbent articles having a pre-formed waistand leg openings. A pant may be donned by inserting a wearer's legs intothe leg openings and sliding the pant into position about the wearer'slower torso. Pants are also commonly referred to as “closed diapers”,“prefastened diapers”, “pull-on diapers”, “training pants” and“diaper-pants.”

FIG. 1 is a plan view of an exemplary, non-limiting embodiment of anabsorbent article 20 of the present invention in a flat, uncontractedstate (i.e., without elastic induced contraction). The garment-facingsurface 120 of the absorbent article 20 is facing the viewer. Theabsorbent article 20 includes a longitudinal centerline 100 and alateral centerline 110. The absorbent article 20 may comprise a chassis22. The absorbent article 20 and chassis 22 are shown to have a firstwaist region 36, a second waist region 38 opposed to the first waistregion 36, and a crotch region 37 located between the first waist region36 and the second waist region 38. The waist regions 36 and 38 generallycomprise those portions of the absorbent article 20 which, when worn,encircle the waist of the wearer. The waist regions 36 and 38 mayinclude elastic elements such that they gather about the waist of thewearer to provide improved fit and containment. The waist regions 36 and38 may include a first waistband 1000 and a second waistband 2000. Thecrotch region 37 is that portion of the absorbent article 20 which, whenthe absorbent article 20 is worn, is generally positioned between thelegs of the wearer.

The outer periphery of chassis 22 is defined by longitudinal edges 12and lateral edges 14. The longitudinal edges 12 may be subdivided into afront longitudinal edge 12 a, which is the portion of the longitudinaledge 12 in the first waist region 36, and a rear longitudinal edge 12 b,which is the portion of the longitudinal edge 12 in the rear waistregion 38. The chassis 22 may have opposing longitudinal edges 12 thatare oriented generally parallel to the longitudinal centerline 100.However, for better fit, longitudinal edges 12 may be curved or angledto produce, for example, an “hourglass” shape diaper when viewed in aplan view. The chassis 22 may have opposing lateral edges 14 that areoriented generally parallel to the lateral centerline 110.

The chassis 22 may comprise a liquid permeable topsheet 24, a backsheet26, and an absorbent core 28 between the topsheet 24 and the backsheet26. The absorbent core 28 may have a body-facing surface and a garmentfacing-surface. The topsheet 24 may be joined to the core 28 and/or thebacksheet 26. The backsheet 26 may be joined to the core 28 and/or thetopsheet 24. It should be recognized that other structures, elements, orsubstrates may be positioned between the core 28 and the topsheet 24and/or backsheet 26. In certain embodiments, the chassis 22 comprisesthe main structure of the absorbent article 20 with other features mayadded to form the composite diaper structure. While the topsheet 24, thebacksheet 26, and the absorbent core 28 may be assembled in a variety ofwell-known configurations, preferred diaper configurations are describedgenerally in U.S. Pat. Nos. 3,860,003; 5,151,092; 5,221,274; 5,554,145;5,569,234; 5,580,411; and 6,004,306.

The topsheet 24 is generally a portion of the absorbent article 20 thatmay be positioned at least in partial contact or close proximity to awearer. Suitable topsheets 24 may be manufactured from a wide range ofmaterials, such as porous foams; reticulated foams; apertured plasticfilms; or woven or nonwoven webs of natural fibers (e.g., wood or cottonfibers), synthetic fibers (e.g., polyester or polypropylene fibers), ora combination of natural and synthetic fibers. The topsheet 24 isgenerally supple, soft feeling, and non-irritating to a wearer's skin.Generally, at least a portion of the topsheet 24 is liquid previous,permitting liquid to readily penetrate through the thickness of thetopsheet 24. The topsheet 24 may include apertures. One topsheet 24useful herein is available from BBA Fiberweb, Brentwood, Tenn. assupplier code 055SLPV09U.

Any portion of the topsheet 24 may be coated with a lotion or skin carecomposition as is known in the art. Examples of suitable lotions includethose described in U.S. Pat. Nos. 5,607,760; 5,609,587; 5,635,191; and5,643,588. The topsheet 24 may be fully or partially elasticized or maybe foreshortened so as to provide a void space between the topsheet 24and the core 28. Exemplary structures including elasticized orforeshortened topsheets are described in more detail in U.S. Pat. Nos.4,892,536; 4,990,147; 5,037,416; and 5,269,775.

The absorbent core 28 may comprise a wide variety of liquid-absorbentmaterials commonly used in disposable diapers and other absorbentarticles. Examples of suitable absorbent materials include comminutedwood pulp, which is generally referred to as air felt creped cellulosewadding; melt blown polymers, including co-form; chemically stiffened,modified or cross-linked cellulosic fibers; tissue, including tissuewraps and tissue laminates; absorbent foams; absorbent sponges;superabsorbent polymers; absorbent gelling materials; or any other knownabsorbent material or combinations of materials. In one embodiment, atleast a portion of the absorbent core is substantially cellulose freeand contains less than 10% by weight cellulosic fibers, less than 5%cellulosic fibers, less than 1% cellulosic fibers, no more than animmaterial amount of cellulosic fibers or no cellulosic fibers. Itshould be understood that an immaterial amount of cellulosic materialdoes not materially affect at least one of the thinness, flexibility,and absorbency of the portion of the absorbent core that issubstantially cellulose free. Among other benefits, it is believed thatwhen at least a portion of the absorbent core is substantially cellulosefree, this portion of the absorbent core is significantly thinner andmore flexible than a similar absorbent core that includes more than 10%by weight of cellulosic fibers. The amount of absorbent material, suchas absorbent particulate polymer material present in the absorbent coremay vary, but in certain embodiments, is present in the absorbent corein an amount greater than about 80% by weight of the absorbent core, orgreater than about 85% by weight of the absorbent core, or greater thanabout 90% by weight of the absorbent core, or greater than about 95% byweight of the core. Non-limiting examples of suitable absorbent coresare described in greater details below.

Exemplary absorbent structures for use as the absorbent core 28 aredescribed in U.S. Pat. Nos. 4,610,678; 4,673,402; 4,834,735; 4,888,231;5,137,537; 5,147,345; 5,342,338; 5,260,345; 5,387,207; 5,397,316; and5,625,222.

The backsheet 26 is generally positioned such that it may be at least aportion of the garment-facing surface 120 of the absorbent article 20.Backsheet 26 may be designed to prevent the exudates absorbed by andcontained within the absorbent article 20 from soiling articles that maycontact the absorbent article 20, such as bed sheets and undergarments.In certain embodiments, the backsheet 26 is substantiallywater-impermeable. Suitable backsheet 26 materials include films such asthose manufactured by Tredegar Industries Inc. of Terre Haute, Ind. andsold under the trade names X15306, X10962, and X10964. Other suitablebacksheet 26 materials may include breathable materials that permitvapors to escape from the absorbent article 20 while still preventingexudates from passing through the backsheet 26. Exemplary breathablematerials may include materials such as woven webs, nonwoven webs,composite materials such as film-coated nonwoven webs, and microporousfilms such as manufactured by Mitsui Toatsu Co., of Japan under thedesignation ESPOIR NO and by EXXON Chemical Co., of Bay City, Tex.,under the designation EXXAIRE. Suitable breathable composite materialscomprising polymer blends are available from Clopay Corporation,Cincinnati, Ohio under the name HYTREL blend P18-3097. Such breathablecomposite materials are described in greater detail in PCT ApplicationNo. WO 95/16746 and U.S. Pat. No. 5,865,823. Other breathable backsheetsincluding nonwoven webs and apertured formed films are described in U.S.Pat. No. 5,571,096. An exemplary, suitable backsheet is disclosed inU.S. Pat. No. 6,107,537. Other suitable materials and/or manufacturingtechniques may be used to provide a suitable backsheet 26 including, butnot limited to, surface treatments, particular film selections andprocessing, particular filament selections and processing, etc.

Backsheet 26 may also consist of more than one layer. The backsheet 26may comprise an outer cover and an inner layer. The outer cover may bemade of a soft, non-woven material. The inner layer may be made of asubstantially liquid-impermeable film. The outer cover and an innerlayer may be joined together by adhesive or any other suitable materialor method. A particularly suitable outer cover is available from CorovinGmbH, Peine, Germany as supplier code A18AH0, and a particularlysuitable inner layer is available from RKW Gronau GmbH, Gronau, Germanyas supplier code PGBR4WPR. While a variety of backsheet configurationsare contemplated herein, it would be obvious to those skilled in the artthat various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention.

The absorbent article 20 may include front ears 40 and/or back ears 42.The ears 40, 42 may be extensible, inextensible, elastic, or inelastic.The ears 40, 42 may be formed from nonwoven webs, woven webs, knittedfabrics, polymeric and elastomeric films, apertured films, sponges,foams, scrims, and combinations and laminates thereof. In certainembodiments the ears 40, 42 may be formed of a stretch laminate such asa nonwoven/elastomeric material laminate or a nonwoven/elastomericmaterial/nonwoven laminate. Stretch laminates may be formed by anymethod known in the art. For example, the ears 40, 42 may be formed as azero strain stretch laminate, which includes at least a layer ofnon-woven material and an elastomeric element. The elastomeric elementis attached to the layer of non-woven material while in a relaxed orsubstantially relaxed state, and the resulting laminate is madestretchable (or more stretchable over a further range) by subjecting thelaminate to an activation process which elongates the nonwoven layerpermanently, but the elastomeric element temporarily. The nonwoven layermay be integral with at least a portion of the chassis 22, in which casethe elastomeric element may be attached to the nonwoven layer and thenon-woven/elastomeric element laminate is subsequently activated.Alternatively, the nonwoven layer may be a separate component, in whichcase the elastomeric element is attached to the nonwoven layer to formthe laminate, which is then coupled to the main portion. If one or morelayers of the side panel are provided separately, the laminate may beactivated either before or after attachment to the main portion. Thezero strain activation processes is further disclosed in U.S. Pat. Nos.5,167,897 and 5,156,793. A suitable elastic ear may be an activatedlaminate comprising an elastomeric film (such as is available fromTredegar Corp, Richmond, Va., as supplier code X25007) disposed betweentwo nonwoven layers (such as is available from BBA Fiberweb, Brentwood,Tenn. as supplier code FPN332).

The ears 40, 42 may be discrete or integral. A discrete ear is formed asseparate element which is joined to the chassis 22. An integral ear is aportion of the chassis 22 that projects laterally outward from thelongitudinal edge 12. The integral ear may be formed by cutting thechassis form to include the shape of the ear projection.

The absorbent article 20 may also include a fastening system 50. Whenfastened, the fastening system 50 interconnects the first waist region36 and the second waist region 38 resulting in a waist circumferencethat may encircle the wearer during wear of the absorbent article 20.The fastening system 50 may comprises a fastener such as tape tabs, hookand loop fastening components, interlocking fasteners such as tabs &slots, buckles, buttons, snaps, and/or hermaphroditic fasteningcomponents, although any other known fastening means are generallyacceptable. Some exemplary surface fastening systems are disclosed inU.S. Pat. Nos. 3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527;5,151,092; and 5,221,274. An exemplary interlocking fastening system isdisclosed in U.S. Pat. No. 6,432,098. The fastening system 50 may alsoprovide a means for holding the article in a disposal configuration asdisclosed in U.S. Pat. No. 4,963,140. The fastening system 50 may alsoinclude primary and secondary fastening systems, as disclosed in U.S.Pat. No. 4,699,622. The fastening system 50 may be constructed to reduceshifting of overlapped portions or to improve fit as disclosed in U.S.Pat. Nos. 5,242,436; 5,499,978; 5,507,736; and 5,591,152.

Waistbands of the present invention may result in absorbent articleshaving increased comfort, fit, and improved leakage performance for thewearer. Certain waistbands may also provide improved product durabilityand strength. The waistbands of the present invention may also result aneasier and improved absorbent article changing experience.

One object of the present invention is to deliver an absorbent articlehaving improved gap closure in the first and/or second waist regions ofthe absorbent article than what is currently known in the art today.Having gap closure in the waist regions may create an article withbetter fit and containment, resulting in improved leakage performance.One way to achieve gap closure is to provide a waistband that is flushcoterminous with the rear lateral edge of the absorbent article. Becausethere is variation in the application process, in some embodiments, awaistband may be present in both the first and second waist regions ofthe absorbent article. However, while a highly contracted waistband isdesirable for the back waist region to provide stretch, it may be moredesirable to have a less contracted waistband in the front waist regionto aid in application. Therefore, one embodiment of the presentinvention is directed to “differential contraction” or waistbandlaminates having different installed elongation strands in the frontversus the back, such that only one waistband laminate is cut. Cuttingof the waistband laminate is subsequent to the waistband application tothe article; the waistband is applied such that it spans the intendedarticle separation (cut) zone. Thus, the same waistband laminate candeliver different levels of contraction in the back and front, resultingin higher contraction in the back to help close the gap and lowercontraction in the front.

In one embodiment, the first (1000) and second waistbands (2000) arecomprised of a waistband laminate (3000). In one embodiment, thewaistband laminate is comprised of a nonwoven material (3100). In oneembodiment, the waistband laminate is comprised of a film. In oneembodiment, the waistband laminate is comprised of at least two elasticstrands (3200), at least four elastic strands, at least six elasticstrands, at least eight elastic strands, at least ten elastic strands,at least twelve elastic strands.

In one embodiment, the first and second waistbands are applied to thearticle at the same applied waistband strain. In one embodiment, thefirst waistband and the second waistband are applied to the disposableabsorbent article at a strain of greater than about 30%, greater thanabout 50%, greater than about 70% as compared to the relaxed length. Inone embodiment, the first waistband and the second waistband are appliedto the disposable absorbent article at a strain of less than about 150%,less than about 125%, less than about 100%, less than about 75% ascompared to the relaxed length. In one embodiment, the first waistbandand the second waistband are applied to the disposable absorbent articleat a strain of from about 70% to about 75% as compared to the relaxedlength.

In one embodiment, the waistband laminate is comprised of a nonwovenmaterial and at least two elastic strands, wherein each of the at leasttwo elastic strands are different elastic materials. In one embodiment,the elastic strands have different diameters or cross-sectionalgeometry.

In one embodiment, the waistband laminate is cut after application tothe article between the elastic strands such that a waistband laminatecomprised of at least two elastic strands results in two waistbands eachhaving one elastic strand; a waistband laminate comprised of at leastfour elastic strands results in two waistbands each having two elasticstrands. As shown in FIG. 2, a waistband laminate 3000 comprised of atleast six elastic strands results in two waistbands (1000, 2000) eachhaving three elastic strands when cut (cut line 4000). Further, awaistband laminate comprised of at least eight elastic strands resultsin two waistbands each having four elastic strands, a waistband laminatecomprised of at least ten elastic strands results in two waistbands eachhaving five elastic strands, a waistband laminate comprised of at leasttwelve elastic strands results in two waistbands each having six elasticstrands. In one embodiment, the waistband laminate is cut such that thetwo resulting waistbands have an unequal distribution of elastic strandsor having no elastic strands on one side of the cut. For example, awaistband laminate having ten elastic strands may result in onewaistband having six elastics and one waistband having four elastics. Inanother example, a waistband laminate having ten elastic strands mayresult in one waistband having ten elastics and one waistband having noelastics. In one embodiment, the waistband laminate is cut in the centerto create the two waistbands. In one embodiment, the waistband laminateis cut off-center. In one embodiment, the waistband laminate may haveelastic strands spaced equally apart. In one embodiment, the waistbandlaminate may have strands spaced closer together or further apart ascompared to the other elastic strands in the laminate.

In one embodiment, the waistband has a length in the direction parallelto the longitudinal axis of the article of greater than about 12 mm,greater than about 15 mm, greater than about 20 mm. In one embodiment,the waistband has a length in the direction parallel to the longitudinalaxis of the article f less than about 50 mm, less than about 45 mm, lessthan about 40 mm.

In one embodiment, the waistband in a relaxed product has a length inthe direction parallel to the lateral axis of the article of greaterthan about 50 mm, greater than about 75 mm, greater than about 100 mm.In one embodiment, the length in the direction parallel to the lateralaxis of the article of the waistband in a relaxed product is less thanabout 300 mm, less than about 250 mm, less than about 200 mm.

In one embodiment, the CD Length Ratio of the waistband compared to thedistance from one tape to the other tape is less than about 2, less thanabout 1.5, about 1.

In one embodiment, the waistband is on the body-facing surface of thearticle. In one embodiment, the waistband is on the garment-facingsurface of the article. In one embodiment, the waistband is sandwichedin between the layers of the absorbent article. In one embodiment, thewaistband is on the garment-facing surface in either the first or secondwaist regions and on the body-facing surface in either the first orsecond waist regions. In one embodiment, the waistband is on both thebody-facing surface and the garment-facing surface. In one embodiment,the waistband is on either the body-facing surface or the garment-facingsurface and the surface not comprising the waistband is printed with aprinted waistband feature.

In one embodiment, the distance from one tape edge to the other tapeedge is at least about 50% the average length of the baby waistcircumference for an average baby that wears the size of absorbentarticle; at least about 60% the average length; at least about 65% theaverage length.

In one embodiment, the elastic strands of the waistband laminate mayhave different installed elongations within one laminate, thus, afterbeing cut, resulting in a first waistband having a first installedelongation and a second waistband having a second installed elongation;both the first and second waistbands have the same applied waistbandstrain. The installed elongation is the strain at which the elastic isunder relative to the second material that it is combined with (e.g. lowbasis weight nonwoven). For example, if the elastic is stretched from100 mm to 250 mm when it is combined with the nonwoven, it would be saidto be 150% installed elongation or ((250 mm/100 mm)−1)×100%. Thislaminate can then be allowed to relax and will return to about theoriginal 100 mm, but with 250 mm of nonwoven. There can be more than oneinstalled elongation within one waistband laminate if the elastics arestrained to a different degree. For example, strand (1) is stretchedfrom 100 mm to 250 mm when combined with the nonwoven or has 150%installed elongation while strand (2) is stretched from 90 mm to 250 mmwhen combined with the NW or has an installed elongation of about 178%.

The Applied Waistband Strain is the strain that the waistband laminateis under when combined with the absorbent article. For example if 100 mmof laminate is stretched to 170 mm when applied it would be consideredto be 70% applied waistband strain or ((170 mm-100 mm)/100 mm×100%). Inone embodiment, the first installed elongation of any number of elasticstrands is about 100%, about 125%, about 140%, about 150%, about 160%,about 175%, about 200%. In one embodiment the second installedelongation of any number of elastic strands is about 100%, about 125%,about 140%, about 150%, about 160%, about 175%, about 200%.

In one embodiment, the delta between the first installed elongation andthe second installed elongation is greater than about 20%, greater thanabout 30%, greater than about 40%.

In one embodiment, the resulting Front-to-Back Delta Chassis Contractionis greater than about 5.0%, greater than about 9.0%, greater than about9.5%, greater than about 12.5%, greater than about 15%, greater thanabout 20%.

In one embodiment, the Front-to-Back Delta Chassis Contraction is lessthan about 15%, less than about 12.5%, less than about 10%, less thanabout 9.5%, less than about 9% when either the front chassis contractionor the back chassis contraction is greater than about 18%, greater thanabout 20%.

Another object of the present invention is to deliver a better balanceof thickness (caliper)/cushion and contraction in a waistband than whatis currently known in the art. Presently, most waistbands are eitherfoam based which have good cushion/caliper for comfort and containmentbut are limited in the amount of contraction or the waistbands are acombination of elastic strands and nonwoven where the elastic strandsare pulled at high strain which delivers high contraction, but verylittle caliper/cushion in use. Thus, one embodiment of the presentinvention is directed to “consolidation” which provides a waistbandhaving the nonwoven material and the elastic strand(s) combined under ahigher first strain (installed elongation) and the resulting waistbandattached to the article under a lower applied waistband strain, suchthat the folded up nonwoven in the waistband provides a cushion/caliperin both the relaxed and stretched/in use states. FIG. 9 depicts crosssectional views of the waistband laminate (3000). FIGS. 9a-b depictcross sections of the waistband with no extended consolidation. FIG. 9adepicts a relaxed product cross section at the waist, parallel to thelateral axis of the diaper chassis (22). FIG. 9b shows an extendedproduct cross section at the waist, parallel to the lateral axis of thediaper. FIGS. 9c-d depict cross sections of the waistband with extendedconsolidation. FIG. 9c shows a relaxed product cross section at thewaist, parallel to the lateral axis of the diaper. FIG. 9c shows thatthe frequency and amplitude of the waistband is higher than that of thechassis it is applied to. FIG. 9d shows an extended product crosssection at the waist, parallel to the lateral axis of the diaper. FIG.9d shows that even when the chassis is extended, the waistband still hasgathers and caliper.

In one embodiment, the waistband is comprised of a laminate comprising anonwoven material and at least one elastic strand, wherein the nonwovenmaterial and the elastic strand(s) are combined under a first strain andthe waistband is attached to the article under an applied waistbandstrain. In one embodiment, the first strain, also referred to as theinstalled strand elongation, is greater than about 50%, greater thanabout 75%, greater than about 100%, greater than about 150%, greaterthan about 200%, greater than about 225%, greater than about 250%,greater than about 300%, greater than about 350%, greater than about375%. In one embodiment, the applied waistband strain, also referred toas the waistband strain is greater than about 25%, greater than about50%, greater than about 75%, greater than about 100%. In one embodiment,the difference between the first strain and the applied waistbandstrain, also referred to as Consolidation, is greater than about 0%,greater than about 65%, greater than about 75%, greater than about 100%,greater than about 150%, greater than about 200%, greater than about225%, greater than about 250%, greater than about 300%.

In one embodiment, the waistband has a Full Waistband Consolidationgreater than about 95%, greater than about 100%, greater than about125%, greater than about 150%, greater than about 175%, greater thanabout 200%.

In one embodiment, the waistband had an Extended Waistband Consolidationgreater than about 35%, greater than about 50%, greater than about 75%,greater than about 100%, greater than about 125%, greater than about175%.

In one embodiment, the waistband is attached near the waist edge. In oneembodiment, the waistband is attached within 20 mm of the waist edge. Inone embodiment, the waistband is attached flush with the waist edge. Inone embodiment, the waistband is present only at one waist edge. In oneembodiment, the waistband is present at both the first and secondwaistband edges.

The nonwoven material and the elastic strand(s) may be combined withadhesive, mechanical bonds, or any other forms of attachment known inthe art. The waistband may be attached to the article with adhesive,mechanical bonds, or any other forms of attachment known in the art.

In one embodiment, the relaxed caliper of the waistband is greater thanabout 1.60 mm, greater than about 2.00 mm, greater than about 2.25 mm,greater than about 2.50 mm.

In one embodiment, the extended caliper of the waistband is greater thanabout 0.80 mm, greater than about 1.00 mm, greater than about 1.25 mm.

Another object of the present invention is to deliver an integrated leggasketing system and front/back waistband feature that provides extraleakage protection around the perimeter of the article. Thus, oneembodiment of the present invention is directed to “360 LeakageProtection” which provides a common leg gasketing system and waistbandwith similar construction having similar gather counts. Additionalembodiments may include leg gasketing systems and waistbands thatoverlap or have similar tints, textures, bond patterns, colors, or othervisual cues. FIG. 3 depicts an embodiment having gathers in both thewaistband regions and leg gasketing system.

In one embodiment, the disposable absorbent article comprising awaistband and a leg gasketing system, as described herein, wherein theleg gasketing system has a first gather count and the waistband has asecond gather count such that the ratio of the first gather count to thesecond gather count is greater than about 0.5, greater than about 0.75,less than about 1.25, less than about 1.50. In one embodiment, the ratioof the first gather count to the second gather count is about 1.00. Inone embodiment, the ratio of the first gather count to the second gathercount is from about 0.75 to about 1.25. In one embodiment, the ratio ofthe first gather count to the second gather count is from about 0.75 toabout 1.25, when the leg gasketing system gather count is greater thanabout 13. In one embodiment, the ratio of the first gather count to thesecond gather count is from about 0.75 to about 1.25, when the waistbandgather count is greater than about 12. In one embodiment, the ratio ofthe first gather count to the second gather count is from about 0.75 toabout 1.25, when the absorbent article is a taped-type product.

In one embodiment, both of the waistband and leg gasketing systemcomprise elastic strands; in one embodiment, the waistband compriseselastic strands; in one embodiment, both the waistband and leg gasketingsystem comprise the same type of stretch material and/or laminatestructure.

In one embodiment, the waistband has greater than about 10 gathers per30 mm section, greater than about 12 gathers per 30 mm section. In oneembodiment, the leg gasketing system has greater than about 10 gathersper 30 mm section, greater than about 12 gathers per 30 mm section.

In one embodiment, the waistband is present in the first waist edge andthe second waist edge and the leg gasketing system is present in thefirst longitudinal edge and the second longitudinal edge.

The absorbent article 20 may include a leg gasketing system 70 asdescribed in U.S. Patent Applications Nos. 61/480,663 and 61/480,670,both filed on Apr. 29, 2011. FIGS. 4 and 5 depict schematic crosssection views of exemplary leg gasketing systems. The leg gasketingsystem 70 may comprise an inner barrier leg cuff 71 comprising an innercuff folded edge 72 and an inner cuff material edge 73. The leggasketing system 70 may further comprise an outer cuff 74 comprising anouter cuff folded edge 75 and an outer cuff material edge 76.

In one embodiment, the leg gasketing system 70 comprises one web ofmaterial. An embodiment having one web of material may provide a costadvantage over embodiments having more than one web of material.Further, an embodiment having one web of material may have fewer leaks,as there are no holes created by bonding more than one web of material.Also, an embodiment having one web of material may be more aestheticallypleasing, as few mechanical bonds are visible.

In one embodiment, the leg gasketing system 70 has an inner barrier legcuff 71 comprised of an inner cuff folded edge 72 and an inner cuffmaterial edge 73. The leg gasketing system 70 may further comprise anouter cuff 74 comprising an outer cuff folded edge 75 and an outer cuffmaterial edge 76. In one embodiment, the web of material is foldedlaterally inward to form the outer cuff folded edge 75 and foldedlaterally outward to form the inner cuff folded edge 72. In oneembodiment, the leg gasketing system 70 extends from the first waistedge 36 to the second waist edge 38 and is joined to the topsheet 24and/or backsheet 26 between the inner cuff folded edge 72 and the outercuff folded edge 75 in the crotch region 37. In one embodiment, theouter cuff material edge 76 is disposed laterally inboard the inner cuffmaterial edge 73.

In one embodiment, the outer leg cuff 74 comprises elastic members 77positioned in a lateral array between the outer cuff folded edge 75 andouter cuff material edge 76; the outer leg cuff 74 optionally comprisesat least two elastic members 77, at least three elastic member 77, atleast four elastic members 77, at least five elastic members 77, atleast six elastic members 77. In one embodiment, the elastic members 77may be disposed between the outer cuff folded edge 75 and the inner cuffmaterial edge 73.

In one embodiment, the inner barrier leg cuff 71 comprises an array ofelastic members 78 in the area of the inner cuff folded edge 72; theinner barrier leg cuff 71 optionally comprises at least one elasticmember 78, at least two elastic members 78, at least three elasticmembers 78, at least four elastic members 78, at least five elasticmembers 78. In one embodiment, the elastic members 78 may be disposedbetween the inner cuff folded edge 72 and the outer cuff material edge76.

In one embodiment, the leg gasketing system 70 has an inner barrier legcuff 71 comprised of an inner cuff folded edge 72 and an inner cuffmaterial edge 73. The leg gasketing system 70 may further comprise anouter cuff 74 comprising an outer cuff folded edge 75 and an outer cuffmaterial edge 76. The leg gasketing system may comprise a first materialcomprising the inner barrier leg cuff 71 and a second materialcomprising the outer cuff 74. The first and second material may overlapand be joined together along a longitudinal edge of each material by anysuitable bonding means. In one embodiment, the web of material is foldedlaterally inward to form the outer cuff folded edge 75 and foldedlaterally outward to form the inner cuff folded edge 72. In oneembodiment, the proximal edges of the outer cuff 74 are coterminous.

One advantage of the leg gasketing system 70 of the present invention isthat when a substantially liquid-impervious material is used inconstruction of the cuff, the polymeric film layer may be narrowed ornot present at all, resulting in more cost effective designs. Utilizingadhesive technologies that are more reliably processed results in morereliable performance and creates substantially liquid impervious seals.This technology enables narrowing the film layer to be only slightlywider than the absorbent core by reducing the need for redundant seals.

In one embodiment of the present invention, the backsheet polymeric filmis less than about 50 mm wider than the absorbent core; optionally lessthan about 40 mm wider, less than about 30 mm wider. In one embodiment,the backsheet polymeric film is at lest about 20 mm more narrow than thechassis width; optionally at least about 40 mm more narrow than thechassis width; optionally at least about 60 mm more narrow than thechassis width; optionally at least about 80 mm more narrow than thechassis width; optionally at least about 100 mm more narrow than thechassis width; optionally at least about 120 mm more narrow than thechassis width.

In one embodiment of the present invention, an opacity strengtheningpatch 80 may be included. The opacity strengthening patch 80 is anadditional layer of material. The opacity strengthening patch 80 may beconnected to the leg gasketing system 70, the polymeric film layer, orthe backsheet 26. The opacity strengthening patch 80 may be disposedbetween the backsheet 26 and leg gasketing system 70 in either the firstwaist region 36, the second waist region 38, or both the first waistregion 36 and the second waist region 38 of the article; the opacitystrengthening patch 80 may overlap at least one of the leg gasketingsystem 70 or the polymeric film layer. The opacity strengthening patch80 may be attached to one or both of the leg gasketing system 70 or thepolymer film layer using any suitable means such as glue, mechanicalbonds, thermal bonds, or the like, so that loads generated during theapplication process or during wear can be transferred from the lateraledge of the article to the leg gasketing system 70 and/or the polymericfilm layer. The opacity strengthening patch is useful in providing thestrength needed to prevent the article from extending excessively duringapplication and wearing; it also may provide opacity at the sides andwaist to prevent the skin of the user from showing through the article.Thus, the patch 80 may be located at any portion of the chassis wherestrength and opacity is desirable. Materials suitable to act as theopacity strengthening patch include materials having a basis weight ofat least about 10 gsm, at least about 15 gsm, at least about 25 gsm. Anopacity strengthening patch useful herein may exhibit the followingtensile properties in the cross direction: at 2% engineering strain fora 1 inch wide sample, 0.4 N; at 5% engineering strain for a 1 inch widesample, 1.25 N; at 10% engineering strain for a 1 inch wide sample, 2.5N. One opacity strengthening patch useful herein is available fromPegas, Znojmo, CZ, as supplier number 803968.

In one embodiment, the material of the leg gasketing system 70 is madefrom a substantially liquid impervious material. The material may beselected from the group consisting of an SMS nonwoven, SMMS nonwovenmaterial, or a nonwoven component layer comprising “N-fibers”.

Various nonwoven fabric webs may comprise spunbond, meltblown, spunbond(“SMS”) webs comprising outer layers of spunbond thermoplastics (e.g.,polyolefins) and an interior layer of meltblown thermoplastics. In oneembodiment of the present invention, the leg gasketing cuff 70 comprisesa nonwoven component layer having fine fibers (“N-fibers”) with anaverage diameter of less than 1 micron (an “N-fiber layer”) may be addedto, or otherwise incorporated with, other nonwoven component layers toform a nonwoven web of material. In some embodiments, the N-fiber layermay be used to produce a SNS nonwoven web or SMNS nonwoven web, forexample. N-fibers are further discussed in WO 2005/095700 and U.S.patent application Ser. No. 13/024,844.

In one embodiment, an absorbent article includes an absorbent core 28that is substantially cellulose free, as described in U.S. Pat. Nos.7,750,203; 7,744,576, and U.S. Patent Publication No. 2008/0312617A1.Cross-sectional views of examples of suitable absorbent cores areschematically represented in FIGS. 6-8. In one embodiment, an absorbentcore 28 comprises first and second layers of material 281, 282 and anabsorbent material 283 disposed between the first and second layers 281,282. In one embodiment the first and second layers of material can be afibrous material chosen from at least one of a nonwoven fibrous web, awoven fibrous web and a layer of thermoplastic adhesive material.Although the first and second layers can be made of a same material, inone embodiment, the first layer 281 is a nonwoven fibrous web and thesecond layer 282 is a layer of thermoplastic adhesive material. Anonwoven fibrous web 281 can include synthetic fibers, such asmono-constituent fibers of PE, PET and PP, multi-constituent fibers suchas side by side, core/sheath or island in the sea type fibers. Suchsynthetic fibers may be formed via a spunbonding process or ameltblowing process. The nonwoven fibrous web 281 may include a singlelayer of fibers but it may also be advantageous to provide the nonwovenweb with multiple layers of fibers such as multiple layers of spunbondfibers, multiple layers of meltblown fibers or combinations ofindividual layer(s) of spunbond and meltblown fibers. In one embodiment,the nonwoven web 281 can be treated with an agent (such as a surfactant)to increase the surface energy of the fibers of the web. Such an agentrenders the nonwoven web more permeable to liquids such as urine. Inanother embodiment, the nonwoven web can be treated with an agent (suchas a silicone) that lowers the surface energy of the fibers of thenonwoven web. Such an agent renders the nonwoven web less permeable toliquids such as urine.

The first layer 281 comprises a first surface 2811 and a second surface2812 and at least regions 2813 of the first surface are in direct facialrelationship with a significant amount of absorbent material 283. In oneembodiment an absorbent material is deposited on the first surface 2811in a pattern to form regions 2813 on the first layer 281, which are indirect facial relationship with a significant amount of absorbentpolymer material 283 and regions 2814 on the first web that are infacial relationship with only an insignificant amount of absorbentmaterial. By “direct facial relationship with a significant amount ofabsorbent material” it is meant that some absorbent material isdeposited on top of the regions 2813 at a basis weight of at least 100g/m², at least 250 g/m² or even at least 500 g/m². The pattern mayinclude regions that all have the same shape and dimensions (i.e.projected surface area and/or height). In the alternative the patternmay include regions that have different shape or dimensions to form agradient of regions.

In one embodiment, the second layer 282 is a layer of a thermoplasticadhesive material. “Thermoplastic adhesive material” as used herein isunderstood to mean a polymer composition from which fibers are formedand applied to the absorbent material with the intent to immobilize theabsorbent material in both the dry and wet state. Non-limiting examplesof thermoplastic adhesive material may comprise a single thermoplasticpolymer or a blend of thermoplastic polymers. The thermoplastic adhesivematerial may also be a hot melt adhesive comprising at least onethermoplastic polymer in combination with other thermoplastic diluentssuch as tackifying resins, plasticizers and additives such asantioxidants. In certain embodiments, the thermoplastic polymer hastypically a molecular weight (Mw) of more than 10,000 and a glasstransition temperature (Tg) usually below room temperature or −6°C.>Tg<16° C. In certain embodiments, typical concentrations of thepolymer in a hot melt are in the range of about 20 to about 40% byweight. Exemplary polymers are (styrenic) block copolymers includingA-B-A triblock structures, A-B diblock structures and (A-B)n radialblock copolymer structures wherein the A blocks are non-elastomericpolymer blocks, typically comprising polystyrene, and the B blocks areunsaturated conjugated diene or (partly) hydrogenated versions of such.The B block is typically isoprene, butadiene, ethylene/butylene(hydrogenated butadiene), ethylene/propylene (hydrogenated isoprene),and mixtures thereof. Other suitable thermoplastic polymers that may beemployed are metallocene polyolefins, which are polymers prepared usingsingle-site or metallocene catalysts. In exemplary embodiments, thetackifying resin has typically a Mw below 5,000 and a Tg usually aboveroom temperature, typical concentrations of the resin in a hot melt arein the range of about 30 to about 60% by weight, and the plasticizer hasa low Mw of typically less than 1,000 and a Tg below room temperature,with a typical concentration of about 0 to about 15%.

The thermoplastic adhesive material 282 can be disposed substantiallyuniformly within the absorbent material 283. In the alternative, thethermoplastic adhesive material 282 can be provided as a fibrous layerdisposed on top of the absorbent material 283 and the regions 2814 ofthe first surface 2811 that are in facial relationship with only aninsignificant amount of absorbent material. In one embodiment, athermoplastic adhesive material is applied at an amount of between 1 and20 g/m², between 1 and 15 g/m² or even between 2 and 8 g/m². Thediscontinuous deposition of absorbent material on the first layer 281imparts an essentially three-dimensional structure to the fibrous layerof thermoplastic material 282. In other words, the layer ofthermoplastic adhesive material follows the topography resulting fromthe absorbent material 283 deposited on the first nonwoven fibrous web281 and the regions 2814 that only include insignificant amounts ofabsorbent material. Without intending to be bound by any theory, it isbelieved that the thermoplastic adhesive materials disclosed hereinenhance immobilization of the absorbent material in a dry and wet state.

In one embodiment, the absorbent core 28 may further comprise a secondlayer of a nonwoven fibrous material 284. This second layer may beprovided of the same material as the nonwoven fibrous layer 281, or inthe alternative may be provided from a different material. It may beadvantageous for the first and second nonwoven fibrous layers 281, 284to be different in order to provide these layers with differentfunctionalities.

The regions 2813 may have any suitable shape in the x-y dimension of theabsorbent core. In one embodiment, the regions 2813 form a pattern ofdisc that are spread on the first surface of the first web 281. In oneembodiment, the regions 2813 form a pattern of longitudinal “strips”that extend continuously along the longitudinal axis of the absorbentcore (i.e. along the y dimension). In an alternative embodiment, thesestrips may be are arranged to form an angle of at between 10 and 90degrees, between 20 and 80 degrees, between 30 and 60 degrees, or even45 degrees relative to the longitudinal axis of the absorbent article.

In one embodiment, the second nonwoven layer 284 has a first surface2841 and a second surface 2842 and an absorbent material 283 applied toits first surface 2841 in order to form a pattern of regions 2843 thatare in direct facial relationship with a significant amount of absorbentmaterial 283 and regions 2844 on the first surface 2841 that are infacial relationship with only an insignificant amount of absorbentmaterial as previously discussed. In one embodiment, a thermoplasticadhesive material 285 may further be applied on top of the secondnonwoven layer 284 as previously discussed in the context of the firstweb/absorbent material/thermoplastic adhesive material composite. Thesecond nonwoven layer 284 may then be applied on top of the firstnonwoven layer 281. In one embodiment, the pattern of absorbent materialpresent on the second nonwoven layer 284 may be the same as the patternof absorbent material present on the first nonwoven layer 281. In another embodiment, the patterns of absorbent material that are present onthe first and second nonwoven layers are different in terms of at leastone of the shape of the regions, the projected surface areas of theregions, the amount of absorbent material present on the regions and thetype of absorbent material present on the regions.

The absorbent core 28 may also comprise an auxiliary adhesive which isnot illustrated in the figures. The auxiliary adhesive may be depositedon at least one of or even both the first and second nonwoven layers281, 284 before application of the absorbent material 283 in order toenhance adhesion of the absorbent material as well as adhesion of thethermoplastic adhesive material 282, 285 to the respective nonwovenlayers 281, 284. The auxiliary adhesive may also aid in immobilizing theabsorbent material and may comprise the same thermoplastic adhesivematerial as described hereinabove or may also comprise other adhesivesincluding but not limited to sprayable hot melt adhesives, such as H. B.Fuller Co. (St. Paul, Minn.) Product No. HL-1620-B. The auxiliaryadhesive may be applied to the nonwoven layers 281, 284 by any suitablemeans, but according to certain embodiments, may be applied in about 0.5to about 1 mm wide slots spaced about 0.5 to about 2 mm apart.Non-limiting examples of suitable absorbent material 283 includeabsorbent polymer material such as cross linked polymeric materials thatcan absorb at least 5 times their weight of an aqueous 0.9% salinesolution as measured using the Centrifuge Retention Capacity test (Edana441.2-01). In one embodiment, the absorbent material 283 is absorbentpolymer material which is in particulate form so as to be flowable inthe dry state.

EXAMPLES

Differential Contraction

Front Back Waist Front Waist Back Front-to- Relaxed Stretched FrontRelaxed Stretched Back Back Delta Chassis Chassis Chassis ChassisChassis Chassis in Chassis Width Width Contraction Width WidthContraction Contraction (mm) (mm) (%) (mm) (mm) (%) (%) Products RCFWECFW FCC RCBW ECBW BCC Delta CC Anerle 294 330 10.91 296 332 10.84 0.1Diaper (1) Parents 251 286 12.24 247 288 14.24 2.0 Choice Diaper (2)Moony 202 232 12.93 197 238 17.23 4.3 Diaper (3) Huggies 296 340 12.94299 335 10.75 2.2 Baby Steps (4) Huggies 251 270 6.91 231 270 14.34 7.4Supreme (5) Drypers (6) 300 350 14.29 284 332 14.46 0.2 (1) Anerle TapedDiaper from Philippines, Size L (9-13 kg), SKU 90324495220, Lot 20121009WP071157C9236; green foam sandwiched waistband (2) Parents Choice TapedDiaper (2) from North America, Lot 9344 M02 1759 S-1855; white foamsandwiched waistband (3) Moony Taped Diaper from Japan, Lot 910193071;green foam sandwiched waistband (4) Huggies Baby Steps US, 1991, Size 4,Lot 3U251910248; white foam sandwiched waistband in blue film (5)Huggies Supreme 2001, Size 4, Lot NM127501F0755; green nonwovenwaistband with small denier elastic strands in white film (6) Drypers,US, Size Large, Sep. 8, 1998; white foam sandwiched waistband white filmFront Back Waist Front Waist Back Front-to- Relaxed Stretched FrontRelaxed Stretched Back Back Delta Chassis Chassis Chassis ChassisChassis Chassis Chassis Width Width Contraction Width Width ContractionContraction (mm) (mm) (%) (mm) (mm) (%) (%) Examples RCFW ECFW FCC RCBWECBW BCC Delta CC A 171 212.2 24.1 160 212.4 32.8 8.7 B 175.2 212.6 21.3165.2 212.6 28.7 7.3 C 179.6 212.6 18.4 166.2 212.6 27.9 9.5 D 179.4212.4 18.4 164.2 212.8 29.6 11.2 E 191.2 212.4 11.1 163.6 212.4 29.818.7 F 184.6 212.2 15.0 170.6 212.6 24.6 9.7 G 199.4 212.2 6.4 163.6212.6 30.0 23.5 H 192.4 212.6 10.5 165 213 29.1 18.6 I 201.6 212.4 5.4165 212.4 28.7 23.4 J 208.8 212.8 1.9 164.2 212.8 29.6 27.7 A—InstalledElongation: 150%; Waistband Strain: 150%; Delta Front/Back InstalledElongation: 0 B—Installed Elongation: 200%; Waistband Strain: 200%;Delta Front/Back Installed Elongation: 0 C—Installed Elongation: 150%;Waistband Strain: 130%; Delta Front/Back Installed Elongation: 20D—Installed Elongation: 200%; Waistband Strain: 180%; Delta Front/BackInstalled Elongation: 20 E—Installed Elongation: 150%; Waistband Strain:110%; Delta Front/Back Installed Elongation: 40 F—Installed Elongation:200%; Waistband Strain: 160%; Delta Front/Back Installed Elongation: 40G—Installed Elongation: 150%; Waistband Strain: 100%; Delta Front/BackInstalled Elongation: 50 H—Installed Elongation: 200%; Waistband Strain:140%; Delta Front/Back Installed Elongation: 60 I—Installed Elongation:200%; Waistband Strain: 120%; Delta Front/Back Installed Elongation: 80J—Installed Elongation: 200%; Waistband Strain: 100%; Delta Front/BackInstalled Elongation: 100Consolidation

Extended Relaxed Total Full Extended Relaxed Extended Length LengthLength Waistband Waistband Caliper Caliper CEL RWL EWL ConsolidationConsolidation Products (mm) (mm) (mm) (mm) (mm) (%) (%) Huggies Snug &0.91 0.55 237 172 273 59 −14 Dry (7) Huggies Little 1.08 0.61 223 155241 56 −14 Movers (8) Huggies 1.45 0.70 220 131 253 93 33 Overnight (9)K 1.64 0.40 205 125 201 60 −1 L 2.24 0.71 208 132 286 116 53 M 2.40 1.04203 130 340 162 98 N 2.54 1.01 205 131 386 195 131 O 2.22 1.29 205 126425 237 176 (7) Huggies Snug & Dry, size 4; Lot No. BI 103108B (8)Huggies Little Movers, size 3; Lot No. BI 024610B (9) Huggies Overnight,size 4; Lot No. PA 027104F K—75% Installed Elongation and 75% WaistbandStrain L—150% Installed Elongation and 75% Waistband Strain M—225%Installed Elongation and 75% Waistband Strain N—300% InstalledElongation and 75% Waistband Strain O—375% Installed Elongation and 75%Waistband Strain360 Leakage Protection

Ratio of Leg Average Leg Average Gasketing System Gasketing WaistbandGather Count to System Gather Waistband Gather Products Gather CountCount Count P 20.7 22.2 0.9 Q 21.2 21.2 1.0 R 16.7 18.2 0.9 Huggies BabySteps (4) 23.2 12.5 1.9 Huggies Supreme (5) 17.0 24.0 0.7 Anerle Diaper(1) 20.0 16.0 1.3 Parent Choice (2) 20.0 15.5 1.3 Moony Diaper (3) 12.511.2 1.1 P—150% Installed Elongation, 75% Waistband Strain R—150%Installed Elongation, 75% Waistband Strain Q—150% Installed Elongation,75% Waistband StrainTest MethodsChassis Contraction Method

The chassis contraction is measured using a calibrated ruler capable ofmeasuring to ±1 mm, (traceable to National standards such as NIST), anda force gauge capable of measuring an applied force of 500 g accuratelyto ±0.5 g (a suitable gauge is the Chatillon DFS series, available fromAmetek, Largo, Fla.). A spring loaded clamp, with contact faces 60 mmwide by 10 mm deep, is attached to the force gauge to hold the testarticle. All testing is performed in a room maintained at about 23±2° C.and about 50±2% relative humidity. All samples were conditioned for 2hours before testing at about 23±2° C. and about 50±2% relativehumidity.

For this measure the chassis is identified as the portion of the articlewith contiguous back sheet and does not include any attached tabs orattached elastic tabs/ears. Unfold the absorbent article taking care notto stretch the waist features. Place it on a horizontal bench surfacewith the back sheet facing the bench and the top sheet facing upward. Ifpresent, unfold and lie flat any tabs or ears attached to the back halfof the article. Identify the back waist feature of the article. With thearticle flat against the bench, lay the calibrated ruler along thearticle aligning it with the lateral midline of the waist feature.Measure the lateral distance from the right distal edge of the chassisto the left distal edge of the chassis and record to the nearest 1 mm.This is the Relaxed Back Chassis Width (RBCW)

Attach the force gauge to the right distal edge of the chassis. Asattached, the force gauge is oriented to pull from left to right. Thegrip faces are parallel to the longitudinal axis of the article,centered at the lateral midline of the waist feature, with 3 mm of thechassis within the grip faces.

Adhere a piece of 2-sided adhesive tape 50 mm in width by 900 mm long tothe bench. Hold the article with the back sheet directed toward thetaped surface with the back waist parallel to the long dimension of thetape. Align the lateral midline of the waist feature with the lateralmidline of the tape strip. Secure the first 3 mm of the left chassisedge to the adhesive tape. Using the force gauge, extend the back waistto an applied force of 500 g. Next lower the article and adhere thearticle's back waist to the adhesive tape across the lateral width ofthe chassis. Remove the force gauge from the chassis. Lay the ruleracross the article aligning it along the lateral midline of the waistfeature. Measure the lateral distance from the right distal edge of thechassis to the left distal edge of the chassis and record to the nearest1 mm. This is the Extended Back Chassis Width (EBCW).

Repeat this measure in like fashion for the front waist feature of thearticle to determine the Relaxed Front Chassis Width (RFCW) and theExtended Front Chassis Width (EFCW). Calculate the Chassis Contractionsas follows:% Back Chassis Contraction (% BCC)=(EBCW−RBCW)/EBCW×100% Front Chassis Contraction (% FCC)=(EFCW−RFCW)/EFCW×100Front-to-Back Delta Chassis Contraction=absolute value of (% BCC−% FCC)Waist Feature Calipers

Calipers were performed using an Ono Sokki digital caliper (GS-503Linear Gauge Sensor with DG-3610 Digital Gauge, Ono Sokki Co, Japan)capable of measuring to 0.01 mm. The foot diameter is 1 cm and theapplied pressure is 0.5 psi. Readings are taken after a residence timeof 5 sec. Linear measurements are made using a calibrated ruler capableof measuring to ±1 mm (traceable to National standards such as NIST). Astainless steel plate, uniformly 1.5 mm thick±0.1 mm, 20 cm wide and 40cm long is used for mounting the extended waist. All testing isperformed in a room maintained at about 23±2° C. and about 50±2%relative humidity. All samples are conditioned for 2 hours beforetesting at about 23±2° C. and about 50±2% relative humidity.

Relaxed Waist Calipers

Unfold an absorbent article taking care not to stretch the waistfeatures. Place it on a horizontal bench surface with the back sheetfacing the bench and the top sheet facing upward. If present, unfold andlie flat any tabs or ears attached to the back half of the article.Identify the back waist feature of the article. Using a calibrated rulermeasure the lateral width of the waist feature along its longitudinalmidline. This is the Relaxed Length of the waist feature (RWL) Mark thewaist feature along its midline at 50% of its lateral width. This iswaist site 1 (WS1). Measure and mark two more sites, the first 1.5 cm tothe left of the 50% mark (WS2) and the second 1.5 cm to the right of the50% mark (WS3).

Place the caliper on the anvil and zero the digital controller. Placethe article on the anvil, with the top sheet facing upward, and use thecaliper to measure the thickness at WS1, WS2, and WS3. Report to thenearest 0.01 mm as the Relaxed Waist Caliper RWC1, RWC2, and RWC3respectively.

Using a cryogenic freeze spray (available as CytoFreeze, ControlCompany, TX) gently remove the elastic feature from the article. Placethe article on the anvil, with the top sheet facing upward, and use thecaliper to measure the thickness of the article corresponding to WS1,WS2, and WS3. Report to the nearest 0.01 mm as Relaxed Back SheetCaliper RBC1, RBC2, RBC3 respectively.

Calculate the Waist Feature Caliper as:Relaxed Waist Feature Caliper=[(RWC1−RBC1)+(RWC2−RBC2)+(RWC3−RBC3)]/3

Repeat this procedure for three identical articles and report as theaverage to the nearest 0.01 mm.

Extended Waist Calipers

Unfold an absorbent article taking care not to stretch the waistfeatures. Assemble a vertical ring stand which supports a horizontalbar. Attach a spring loaded clamp to the left edge of the chassis,centered on the waist feature. Attach the clamp to the horizontalsupport so that the waist feature hangs vertically. Attach a secondclamp, which has a mass of 300 g±1 g, to the right edge of the chassis,centered on the midline of the waist feature. Allow the article to hangfor 30 seconds and then using the calibrated ruler measure the extendedlength of the waist feature to the nearest 1 mm. This is the ChassisExtended Length (CEL). The CEL can be used for all extended waistmeasures.

Unfold another absorbent article taking care not to stretch the waistfeatures. Place it on a horizontal bench surface with the back sheetfacing the bench and the top sheet facing upward. If present, unfold andlie flat any tabs or ears attached to the back half of the article.Identify the back waist feature of the article. Using a calibrated rulermeasure the lateral width of the waist feature along its longitudinalmidline. This is the Relaxed Length of the waist feature (RWL) Mark thewaist feature along its midline at 50% of its lateral width. This iswaist site 1 (WS1). Measure and mark two more sites, the first 1.5 cm tothe left of the 50% mark (WS2) and the second 1.5 cm to the right of the50% mark (WS3). Identify the proximal edge of the waist feature, i.e.the edge closest to the crotch of the article. Mark a lateral line 1.5cm from the proximal edge toward the crotch, and parallel to the waistfeature. Along a longitudinal axis that passes through WS1, mark theintersection at the lateral line just drawn (AS1). Repeat in likefashion for WS2 and WS3 to define sites AS2 and AS3 respectively.

Place the article, top sheet facing upward, onto the stainless steelplate. Secure the left distal edge of the chassis at the waist feature'smidline to the steel plate with adhesive tape. Grasp the right side ofthe chassis and pull until the waist feature has been extended equal tothe Chassis Extended Length (CEL). Secure the right side of the chassisto the steel plate with adhesive tape.

Place the steel plate with attached article on the anvil of the caliper.Place the caliper foot on a region of the steel plate that is notcovered by the article and zero the digital control. Using the caliper,measure the thickness at the six marked sites. Report to the nearest0.01 mm as Extended Waist Caliper EWC1, EWC2, and EWC3. Using acryogenic freeze spray gently remove the elastic feature from thearticle. Place the steel plate with attached article on the anvil of thecaliper and measure the thickness of the article at the sitescorresponding to WS1, WS2 and WS3. Report to the nearest 0.01 mm asExtended Back Sheet Caliper EBC1, EBC2, EBC3 respectively.

Calculate the Waist Feature Calipers as:Extended Waist Feature Caliper=[(EWC1−EBC1)+(EWC2−EBC2)+(EWC3−EBC3)]/3

Repeat this procedure for three identical articles and report as theaverage to the nearest 0.01 mm.

Waist Feature Percent Consolidation

Linear measurements are made using a calibrated ruler capable ofmeasuring to ±1 mm (traceable to National standards such as NIST). Alltesting is performed in a room maintained at about 23±2° C. and about50±2% relative humidity. All samples are conditioned for 2 hours beforetesting at about 23±2° C. and about 50±2% relative humidity.

Unfold the absorbent article taking care not to stretch the waistfeatures. Place it on a horizontal bench surface with the back sheetfacing the bench and the top sheet facing upward. If present, unfold andlie flat any tabs or ears attached to the back half of the article.Identify the back waist feature of the article. Using a calibrated rulermeasure the lateral width of the waist feature along its midline andrecord to the nearest 1 mm. This is the Relaxed Length of the waistfeature (RWL).

Using a cryogenic freeze spray (available as CytoFreeze, ControlCompany, TX) carefully remove the waist feature from the article. Placethe waist feature into a beaker with 100 mL of dichloromethane and soakfor 15 minutes to dissolve the adhesives. Remove the waist feature fromthe solvent and remove the elastics. Lay the waist feature substrateflat in a fume hood to dry. Assemble a vertical ring stand whichsupports a horizontal bar. Attach a spring loaded clamp, which is atleast as wide as the waist feature, to the left edge of the waistfeature. Attach the clamp to the horizontal support so that the waistfeature hangs vertically. Attach a second clamp, which has a mass of 3g±1 g and is at least as wide as the waist feature, to the right edge ofthe waist feature. Allow the article to hang for 30 seconds and thenusing the calibrated ruler measure the extended length of the waistfeature to the nearest 1 mm. This is the Extended Waist Feature Length(EWL).

Calculate the Full Waistband Consolidation as:% Full Waistband Consolidation=((EWL−RWL)/RWL)×100

Repeat this procedure for three identical articles and report as theaverage to the nearest 1 mm.

Calculate the Extended Waistband Consolidation as:% Extended WaistbandConsolidation=((EWL−RWL)/RWL)×100−((1-((CEL−RWL)/CEL))*100)

Repeat this procedure for three identical articles and report as theaverage to the nearest 1 mm.

Frequency of Waistband and Outer Leg Cuff Gathers on Taped DiaperProducts

In the visual center of the waistband on the diaper both CD and MD,report the number of gathers per 30 mm on both taped end (TE) andun-taped end (UTE). Hold in place the measuring template, as shown inFIG. 10, then count the gather peaks within the 30 mm window on thetemplate. Make sure not to stretch the gathers. Perform this on both thetaped (TE) inside and outside and then repeat on the un-taped end (UTE)inside and outside of the product. Report the number of gathers withinthe 30 mm.

In the visual center of the Leg Gasketing System gather on the diaperboth CD and MD, report the number of gathers per 30 mm on both Babyright and Baby left. Hold in place the measuring template then count thenumber of gathers within the 30 mm window on the template. Make sure notto stretch the gathers. Perform this on both Baby right and Baby left ofthe product both CD and MD. Report the number of gathers within the 30mm.

Calculate the Ratio of Leg Gasketing System Gather Count to WaistbandGather Count as follows:Ratio=Average Leg Gasketing System Gather Count/Average Waistband GatherCount

Repeat this procedure for three identical articles and report as theaverage.

CD Length Ratio

CD Length Ratio is the ratio of chassis extended length (CEL) toExtended Back Chassis Width (EBCW), as defined here.

Calculate the CD Length Ratio as follows:CD Length Ratio=CEL/EBCW

Repeat this procedure for three identical articles and report as theaverage.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numeral values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this written document conflicts with any meaningor definition of the term in a document incorporated by reference, themeaning or definition assigned to the term in this written documentshall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A taped diaper comprising: a first waist region,a second waist region, and a crotch region disposed between the firstwaist region and second waist region; a first waist edge and a secondwaist edge; a first longitudinal edge and a second longitudinal edge; awaistband and a leg gasketing system, wherein the leg gasketing systemextends from the first waist edge to the second waist edge, wherein thewaistband is comprised of a laminate comprising a nonwoven material andat least one elastic strand, wherein the at least one elastic strand hasan installed elongation and an applied waistband strain, the installedelongation being a strain that the at least one elastic strand is underwhen combined with the nonwoven material to form the laminate and theapplied waistband strain being a strain that the laminate is under whencombined with the diaper, wherein the installed elongation is higherthan the applied waistband strain, wherein the waistband has an ExtendedWaist Feature Length (EWL), a Relaxed Length of the Waist Feature (RWL),and a Full Waistband Consolidation of between 95% and 237%, wherein theFull Waistband Consolidation=((EWL−RWL) RWL)×100, and wherein the leggasketing system has a first gather count and the waistband has a secondgather count, such that a ratio of the first gather count to the secondgather count is from 0.75 to 1.25 and the second gather count is between12 and 22.2 per 30 mm.
 2. The diaper of claim 1, wherein the firstgather count is between 13 and 21.1 per 30 mm.
 3. The diaper of claim 1,wherein the waistband has a Chassis Extended Length (CEL), and whereinthe waistband has a ratio of EWL to CEL of greater than 1.16 and lessthan 2.07.
 4. The diaper of claim 3, wherein the first gather count isbetween 13 and 21.1 per 30 mm.
 5. The diaper of claim 2, wherein theratio of the first gather count to the second gather count is 1.00. 6.The diaper of claim 1, wherein the waistband is present in the firstwaist edge and the second waist edge, and wherein the leg gasketingsystem is present in the first longitudinal edge and the secondlongitudinal edge.
 7. The diaper of claim 1, wherein the waistband andthe leg gasketing system are a same color.
 8. The diaper of claim 1,wherein the leg gasketing system comprises an inner cuff and an outercuff; wherein the inner cuff comprises an inner cuff folded edge and aninner cuff material edge; and wherein the outer cuff comprises an outercuff folded edge and an outer cuff material edge, such that a web ofmaterial is folded laterally inward to form the outer cuff folded edgeand folded laterally outward to form the inner cuff folded edge.
 9. Thediaper of claim 1, comprising an apertured topsheet.
 10. A taped diapercomprising: a first waist region comprising a first waistband, a secondwaist region comprising a second waistband, and a crotch region disposedbetween the first waist region and second waist region; a first waistedge and a second waist edge; a first longitudinal edge and a secondlongitudinal edge; and a leg gasketing system, wherein the leg gasketingsystem extends from the first waist edge to the second waist edge,wherein the first waistband is comprised of a first laminate comprisinga nonwoven material and at least one first elastic strand, wherein thesecond waistband is comprised of a second laminate comprising a nonwovenmaterial and at least one second elastic strand, wherein the at leastone first elastic strand has a first installed elongation and a firstapplied waistband strain, the first installed elongation being a strainthat the at least one first elastic strand is under when combined withthe nonwoven material to form the first laminate and the first appliedwaistband strain being a strain that the first laminate is under whencombined with the diaper, wherein the at least one second elastic strandhas a second installed elongation and a second applied waistband strain,the second installed elongation being a strain that the at least onesecond elastic strand is under when combined with the nonwoven materialto form the second laminate and the second applied waistband strainbeing a strain that the second laminate is under when combined with thediaper, wherein the first installed elongation is different from thesecond installed elongation, and wherein the first applied waistbandstrain is the same as the second applied waistband strain.
 11. Thediaper of claim 10, wherein the first waist region, the second waistregion, and the crotch region define a chassis, and wherein: the firstwaist region comprises a Relaxed Front Chassis Width (RFCW) and anExtended Front Chassis Width (EFCW), wherein a % Front ChassisContraction (% FCC)=(EFCW−RFCW)/EFCW×100; the second waist regioncomprises a Relaxed Back Chassis Width (RBCW) and an Extended BackChassis Width (EBCW), wherein % Back Chassis Contraction (%BCC)=(EBCW−RBCW)/EBCW×100; and the diaper comprises a Front-to-BackDelta Chassis Contraction of greater than 5.0% and less than or equal to27.7%, wherein the Front-to-Back Delta Chassis Contraction=(% BCC−%FCC).
 12. The diaper of claim 10, wherein the first installed elongationis higher than the first applied waistband strain, and wherein thesecond installed elongation is higher than the second applied waistbandstrain.
 13. The diaper of claim 10, wherein the leg gasketing system hasa first gather count and the waistband has a second gather count,wherein a ratio of the first gather count to the second gather count isfrom 0.75 to 1.25.